Vehicle interior systems having a cold-bent glass substrate and methods for forming the same

ABSTRACT

Embodiments of a vehicle interior system and methods for forming the same are disclosed. A glass substrate is bent to a curved shape within a mold cavity, and a liquid polymer material is delivered to the mold and is in contact with the curved glass substrate. The liquid polymer is solidified to form a polymer frame that engages the bent glass substrate, and the engagement between the frame and the glass substrate holds the glass substrate in the bent shape. The temperature of the glass substrate during the bending process and formation of the frame are maintained below the glass transition temperature of the glass substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims is a continuation of and claims the benefit ofpriority of U.S. application Ser. No. 16/512,657 filed on Jul. 16, 2019,which the benefit of priority under 35 U.S.C. § 119 of U.S. ProvisionalApplication Ser. No. 62/698,506 filed on Jul. 16, 2018, the content ofwhich is relied upon and incorporated herein by reference in itsentirety.

BACKGROUND

The disclosure relates to vehicle interior systems including a glasssubstrate and methods for forming the same, and more particularly to acold-formed or cold-bent curved glass substrate and methods for formingthe same.

Vehicle interiors include curved surfaces and can incorporate displays,touch panels and/or other cover glass components in such curvedsurfaces. The materials used to form such curved surfaces are typicallylimited to polymers, which do not exhibit the durability and opticalperformance of glass. As such, Applicant has determined that curvedglass substrates are desirable, especially when used as covers fordisplays and/or touch panels. Existing methods of forming such curvedglass substrates, such as thermal forming, have drawbacks including highcost, optical distortion, and surface marking. Applicant has identifieda need for vehicle interior systems that can incorporate a curved glasssubstrate in a cost-effective manner and without problems typicallyassociated with glass thermal forming processes, and while also havingthe mechanical performance to pass industry-standard safety tests andregulations.

SUMMARY

One embodiment of the disclosure relates to a method of forming avehicle interior system. The method includes supporting a glasssubstrate within a mold cavity of a mold. The glass substrate has afirst major surface and a second major surface opposite the first majorsurface, and the second major surface of the glass substrate faces acurved support surface within the mold. The method includes applying aforce to the glass substrate causing the glass substrate to bend intoconformity with a curved shape of the curved support surface such that acurved glass substrate is formed. The first major surface of the curvedglass substrate includes a curved section and the second major surfaceof the curved glass substrate includes a curved section. The methodincludes delivering a liquid polymer material to the mold cavity suchthat the liquid polymer material contacts the first major surface of theglass substrate. The method includes solidifying the liquid polymermaterial within the mold cavity to form a polymer frame engaging thecurved glass substrate. The method includes removing the frame and thecurved glass substrate from the mold, and the engagement between theframe and the curved glass substrate maintains the curved glasssubstrate in the curved shape. A maximum temperature of the glasssubstrate during the supporting step, the applying step, the deliveringstep, the solidifying step and the removing step is less than a glasstransition temperature of the glass substrate.

Another embodiment of the disclosure relates to a method of forming avehicle interior system. The method includes supporting a glasssubstrate within a mold cavity of a mold, and the glass substrate has afirst major surface and a second major surface opposite the first majorsurface. The method includes bending the glass substrate to a curvedshape within the mold cavity such that a curved glass substrate isformed while a maximum temperature of the glass substrate is maintainedbelow a glass transition temperature of the glass substrate. The methodincludes delivering a liquid polymer material to the mold cavity suchthat the liquid polymer material contacts the first major surface of theglass substrate. The method includes solidifying the liquid polymermaterial within the mold cavity to form a polymer frame engaging thecurved glass substrate, and the engagement between the frame and thecurved glass substrate maintains the curved glass substrate in thecurved shape.

Another embodiment of the disclosure relates to a vehicle interiorsystem. The vehicle interior system includes a polymer frame comprisinga curved support surface. The vehicle interior system includes a glasssubstrate directly coupled to the curved support surface of the frame.The glass substrate includes a first major surface, a second majorsurface, a minor surface connecting the first major surface and thesecond major surface and a thickness in a range from 0.05 mm to 2 mm.The glass substrate has a curved shape such that the first major surfaceof the glass substrate includes a curved section and the second majorsurface of the curved glass substrate includes a curved section. Thecurved section of the first major surface includes a first radius ofcurvature greater than 30 mm and less than 5 m. The curved supportsurface of the frame directly engages the first major surface of theglass substrate and the engagement and a rigidity of the polymer framemaintains the curved shape of the glass substrate.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed descriptionwhich follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understanding the natureand character of the claims. The accompanying drawings are included toprovide a further understanding, and are incorporated in and constitutea part of this specification. The drawings illustrate one or moreembodiment(s), and together with the description serve to explainprinciples and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle interior with vehicle interiorsystems, according to exemplary embodiments.

FIG. 2 is a cross-sectional, exploded view of a glass substrate prior tobending and attachment to a curved frame of a vehicle interior system,according to an exemplary embodiment.

FIG. 3 is a cross-sectional view of the glass substrate of FIG. 2following cold bending and attachment to the curved frame of FIG. 2 ,according to an exemplary embodiment.

FIGS. 4A-4F show a process for cold-bending a glass substrate andformation of a curved frame, according to an exemplary embodiment.

FIG. 5 is a front perspective view of the glass substrate of FIGS. 2-4F,according to an exemplary embodiment.

FIG. 6 is a perspective view of a curved glass substrate with multipleconvex and concave curved surfaces, according to an exemplaryembodiment.

DETAILED DESCRIPTION

Reference will now be made in detail to various embodiments, examples ofwhich are illustrated in the accompanying drawings. In general, avehicle interior system may include a variety of different curvedsurfaces that are designed to be transparent, such as curved displaysurfaces and curved non-display glass covers, and the present disclosureprovides articles and methods for forming these curved surfaces from aglass material. Forming curved vehicle surfaces from a glass materialprovide a number of advantages compared to the typical curved plasticpanels that are conventionally found in vehicle interiors. For example,glass is typically considered to provide enhanced functionality and userexperience in many curved cover material applications, such as displayapplications and touch screen applications, compared to plastic covermaterials.

While glass provides these benefits, glass surfaces in vehicle interiorsshould also meet performance criteria for both passenger safety and easeof use. For example, certain regulations (e.g., ECE R 21 & FMVSS201)require vehicle interiors to pass the Headform Impact Test (HIT). TheHIT involves subjecting a vehicle interior component, such as a display,to an impact from a mass under certain specific conditions. The massused is an anthropomorphic headform. The HIT is intended to simulate theimpact of the head of a driver or passenger against the vehicle interiorcomponent. The criteria for passing the test includes the force of thedeceleration of the headform not exceeding 80 g (g-force) for longerthan a 3 ms period, and the peak deceleration of the headform being lessthan 120 g. As used in the context of the HIT, “deceleration” refers tothe deceleration of the headform as it is stopped by the vehicleinterior component. Besides these regulatory requirements, there areadditional concerns when using glass under these conditions. Forexample, it may be desirable for the glass to remain intact and notfracture when subjected to the impact from the HIT. In some cases, itmay be acceptable for the glass to fracture, but the fractured glassshould behave in a way to reduce the chance of causing lacerations on areal human head. In the HIT, laceration potential can be simulated bywrapping the headform in a substitute material representing human skin,such as a fabric, leather, or other material. In this way, lacerationpotential can be estimated based on the tears or holes formed in thesubstitute material. Thus, in the case where the glass fractures, it maybe desirable to decrease the chance of laceration by controlling how theglass fractures.

Accordingly, as will be discussed in more detail below, Applicant hasdeveloped a glass article and related manufacturing processes thatprovide an efficient and cost effective way to form an article, such asa display for a vehicle interior system, utilizing a cold-bent piece ofglass substrate. In general, the manufacturing process discussed hereinprovides for cold-bending of a glass article to a curved shape and thenforming (e.g., through injection molding, resin molding or similarprocess) a curved polymer frame directly onto the curved glass article.In this process, the polymer material of the curved polymer framedirectly engages (e.g., directly bonds to) one or more surfaces of theglass article, and the engagement and rigidity of the frame hold theglass in the curved shape.

In particular embodiments, the glass substrate is bent to the curvedshape within a mold (e.g., supported by a curved mold surface) viaapplication of a force (e.g., via a vacuum chuck, electrostatic chuck, apress, etc.). While in the bent shape, a liquid polymer material isprovided to the mold cavity and is in contact with a surface of the bentglass substrate. Then the polymer material is solidified (e.g., viacooling, curing or the like) to form a curved polymer frame that is indirect engagement (e.g., via bonding) with a surface of the glasssubstrate. The direct engagement and the rigidity of the polymer frameholds the glass substrate in the curved shape once the completed articleis removed from the mold. In this process, use of a separate adhesivematerial is avoided, allowing the process to occur without the need ofan adhesive application step. Further, by utilizing the moldingtechnology and equipment as discussed herein, Applicant believes thathigh-throughput and efficient manufacture of articles including acold-bent cover glass structure is provided in a manner not achievablewith conventional hot glass bending processes.

Further in typical processes, curved glass articles are formed using hotforming processes. As discussed herein a variety of curved glassarticles and processes for making the same are provided that avoid thedeficiencies of the typical glass hot-forming process. For example,hot-forming processes are energy intensive and increase the cost offorming a curved glass component, relative to the cold-bending processdiscussed herein. In addition, hot-forming processes typically makeapplication of glass surface treatments, such as anti-reflectivecoatings, significantly more difficult. For example, many coatingmaterials cannot be applied to a flat piece of glass material prior tothe hot-forming process because the coating material typically will notsurvive the high temperatures of the hot-forming process. Further,application of a coating material to surfaces of a curved glasssubstrate after hot-bending is substantially more difficult thanapplication to a flat glass substrate. In addition, Applicant believesthat by avoiding the additional high temperature heating steps neededfor thermal forming, the glass articles produced via the cold-formingprocesses and systems discussed herein have improved optical propertiesand/or improved surface properties than similarly shaped glass articlesmade via thermal-shaping processes.

Thus, for at least these reasons, Applicant believes that the glassarticle and processes for making the glass articles discussed hereinprovide for various combinations of benefits and properties notpreviously achievable with either non-glass articles for vehicle systemsor with previously developed glass articles.

FIG. 1 shows an exemplary vehicle interior 10 that includes threedifferent embodiments of a vehicle interior system 100, 200, 300.Vehicle interior system 100 includes a frame, shown as center consolebase 110, with a curved surface 120 including a curved display 130.Vehicle interior system 200 includes a frame, shown as dashboard base210, with a curved surface 220 including a curved display 230. Thedashboard base 210 typically includes an instrument panel 215 which mayalso include a curved display. Vehicle interior system 300 includes aframe, shown as steering wheel base 310, with a curved surface 320 and acurved display 330. In one or more embodiments, the vehicle interiorsystem includes a frame that is an arm rest, a pillar, a seat back, afloor board, a headrest, a door panel, or any portion of the interior ofa vehicle that includes a curved surface. In other embodiments, theframe is a portion of a housing for a free-standing display (i.e., adisplay that is not permanently connected to a portion of the vehicle).

The embodiments of the curved glass article described herein can be usedin each of vehicle interior systems 100, 200 and 300. Further, thecurved glass articles discussed herein may be used as curved coverglasses for any of the curved display embodiments discussed herein,including for use in vehicle interior systems 100, 200 and/or 300.Further, in various embodiments, various non-display components ofvehicle interior systems 100, 200 and 300 may be formed from the glassarticles discussed herein. In some such embodiments, the glass articlesdiscussed herein may be used as the non-display cover surface for thedashboard, center console, door panel, etc. In such embodiments, glassmaterial may be selected based on its weight, aesthetic appearance, etc.and may be provided with a coating (e.g., an ink or pigment coating)with a pattern (e.g., a brushed metal appearance, a wood grainappearance, a leather appearance, a colored appearance, etc.) tovisually match the glass components with adjacent non-glass components.In specific embodiments, such ink or pigment coating may have atransparency level that provides for deadfront functionality.

As shown in FIGS. 2-4F, formation of a curved glass article, such as thecover glass for curved display 130, is shown according to exemplaryembodiments. It should be understood that while FIGS. 2-4F are describedin terms of forming curved display 130, the curved glass article ofFIGS. 2-4F may be used in any suitable curved glass application,including any curved glass component of any of the vehicle interiorsystems of FIG. 1 .

Referring to FIGS. 2 and 3 , a frame, shown as center console base 110,includes a curved surface, shown as curved surface 120. Display 130includes a glass article, shown as a cover panel 132. Cover panel 132includes a glass substrate 134. Glass substrate 134 includes a firstmajor surface 136 and a second major surface 138 opposite first majorsurface 136. A minor surface 140 connects the first major surface 136and the second major surface 138, and in specific embodiments, minorsurface 140 defines the outer perimeter of glass substrate 134. Anengagement structure, shown as a melt bond 142, is located between firstmajor surface 136 of glass substrate 134 and console base 110, and aswill be discussed in more detail below, bond 142 is formed from thesolidification of the polymer material that forms base 110, such that abond between glass substrate 134 and curved surface 120 of centerconsole base 110 is formed. In some such embodiments, because of theformation of melt bond 142 during molding of base 110 directly to glasssubstrate 134 following bending, no structural adhesives are used tobond glass substrate 134 to base 110.

In general, cover panel 132 is cold formed or cold bent to the desiredcurved shape via application of a bending force 144. As shown in FIG. 3, following cold bending, cover panel 132 has a curved shape such thatfirst major surface 136 and second major surface 138 each include atleast one curved section having a radius of curvature. In the specificembodiments shown, curved surface 120 of base 110 is a convex curvedsurface. In such embodiments, cover panel 132 is bent such that firstmajor surface 136 defines a concave shape that generally conforms to theconvex curved shape of curved surface 120, and second major surface 138defines a convex shape that generally matches or mirrors the convexcurved shape of curved surface 120. In such embodiments, surfaces 136and 138 both define a first radius of curvature R1 that generallymatches the radius of curvature of curved surface 120 of base 110. Inparticular embodiments, bond 142 and the rigidity of base 110 (followingsolidification) holds glass substrate 134 in the curved shape followingremoval of bending force 144.

In general, R1 is selected based on the shape of the associated vehicleinterior frame, and in general R1 is between 30 mm and 5 m. In addition,glass substrate 134 has a thickness T1 (e.g., an average thicknessmeasured between surfaces 136 and 138) shown in FIG. 2 that is in arange from 0.05 mm to 2 mm. In specific embodiments, T1 is less than orequal to 1.5 mm and in more specific embodiments, T1 is 0.3 mm to 0.7mm. Applicant has found that such thin glass substrates can be coldformed to a variety of curved shapes (including the relatively highcurvature radii of curvature discussed herein) utilizing cold formingwithout breakage while at the same time providing for a high qualitycover layer for a variety of vehicle interior applications. In addition,such a thin glass substrate 134 may deform more readily, which couldpotentially compensate for shape mismatches and gaps that may existrelative to curved surface 120 and/or center console base 110.

In various embodiments, first major surface 136 and/or the second majorsurface 138 of glass substrate includes one or more surface treatmentsor layers, shown as surface treatment 146. Surface treatment 146 maycover at least a portion of the first major surface 136 and/or secondmajor surface 138. Exemplary surface treatments include anti-glaresurfaces/coatings, anti-reflective surfaces/coatings, and a pigmentdesign. In one or more embodiments, at least a portion of the firstmajor surface 136 and/or the second major surface 138 may include anyone, any two or all three of an anti-glare surface, an anti-reflectivesurface, and a pigment design. For example, first major surface 136 mayinclude an anti-glare surface and second major surface 138 may includean anti-reflective surface. In another example, first major surface 136includes an anti-reflective surface and second major surface 138includes an anti-glare surface. In yet another example, major surface138 comprises either one of or both the anti-glare surface and theanti-reflective surface, and second major surface 136 includes thepigment design. As will be discussed in more detail below, in at leastsome embodiments, the material of base 110 contacts and/or bonds to thelayer of glass substrate 134 that defines surface 136.

The pigment design may include any aesthetic design formed from apigment (e.g., ink, paint and the like) and can include a wood-graindesign, a brushed metal design, a graphic design, a portrait, or a logo.The pigment design may be printed onto the glass substrate. In one ormore embodiments, the anti-glare surface includes an etched surface. Inone or more embodiments, the anti-reflective surface includes amulti-layer coating.

Referring to FIGS. 4A-4F, a method of cold forming a glass article, suchas cover panel 132 for display 130, and an associated curved frame isshown. As used herein, the terms “cold-bent,” “cold bending,”“cold-formed” or “cold forming” refers to curving the glass substrate ata cold-form temperature which is less than the glass transitiontemperature of the glass material of glass substrate 134.

As shown in FIG. 4A, a mold 400 includes a first mold body 402 and asecond mold body 404. A mold cavity 406 is defined between opposingsurfaces 408 and 410 of mold bodies 402 and 404, respectively. As can beseen in FIG. 4A, surfaces 408 and 410 have complementary curved shapesused to form the desired curved shapes of the frame and of the glasssubstrate as discussed herein.

As shown in FIGS. 4B and 4C, glass substrate 134 is placed within moldcavity 406 such that it is supported such that first major surface 136faces mold surface 410 and second major surface 138 faces mold surface408. As shown in FIG. 4C, while glass substrate 134 is supported withinmold 400, force 144 is applied to glass substrate 134 causing glasssubstrate 134 to bend into substantial conformity with the curved moldsurface 408 (e.g., R1 is within 10% of the radius of curved mold surface408). It should be understood that while FIG. 4 shows glass substrate134 supported directly by mold surface 408 during application of force144, in other embodiments, glass substrate 134 may be supported via aseparate support structure including a curved support structure locatedwithin mold cavity 406.

As shown in FIG. 4C, application of force 144 causes glass substrate 134to adopt a curved shape, such as the shape shown in FIG. 4C and/ordescribed in various embodiments herein. During application of force 144and throughout the process shown in FIGS. 4A-4F, a maximum temperatureof glass substrate 134 is less than a glass transition temperature ofthe glass material of glass substrate 134. In a particular embodiment,the glass substrate is not actively heated via a heating element,furnace, oven, etc. during bending, as is the case when applyinghot-forming glass to a curved shape. In various embodiments, thetemperature of the glass substrate 134 is maintained below 400 degreesC., 300 degrees C., 200 degrees C. or even 100 degrees C. during theprocess shown in FIGS. 4A-4F and in particular during the application ofthe bending force. In particular, Applicant believes that this approachallows for formation of a curved glass substrate while preservingvarious coatings located on the glass substrate that can be damaged ordestroyed at high temperatures typically associated with glass bendingprocesses.

Force 144 may be applied by a variety of suitable mechanisms to formglass substrate 134 to the curved shape shown in FIG. 4C. In a specificembodiment, force 144 is created by applying an air pressuredifferential across glass substrate 134 within mold cavity 406. In someembodiments, the air pressure differential is formed via a vacuum chuck.In other embodiments, force 144 may be generated via other suitablemechanisms, such as a mechanical press, a vacuum chuck, an electrostaticchuck, etc.

Referring to FIGS. 4B and 4C, in the specific embodiment shown, mold 400is configured to apply a vacuum or suction to glass substrate 134 tobend substrate 134 into the curved shape while within mold cavity 406.In one such embodiment, mold body 402 includes a plurality of channels412 fluidly coupled to a vacuum or suction system shown schematically as414. In this manner an air pressure differential across substrate 134 isformed bending substrate 134 in to conformity with surface 408 of moldbody 402. In some such embodiments, glass substrate 134 blocks channels412 such that the liquid polymer is not drawn into channels 412.

Referring to FIGS. 4D and 4E, before, during and/or after application offorce 144, mold 400 is closed around glass substrate 134 while glasssubstrate 134 is maintained in the curved shape. With mold 400 closed, aliquid polymer material is delivered to mold cavity 406, such that theliquid polymer material is in contact with at least first major surface136 of glass substrate 134. Next, as shown in FIG. 4E, the liquidpolymer material is solidified within the mold cavity to form a frame,such as console base 110, that engages the curved glass substrate. Insome embodiments, the solidification of the liquid polymer materialwhile in contact with glass substrate 134 forms a bond, such as meltbond 142 shown in FIG. 3 , between surface 136 of glass substrate 134and base 110. In such embodiments, the bond may be formed directlybetween the polymer material of base 110 and the material of glasssubstrate 134 that defines first major surface 136, which may be theglass material itself or a coating layer or material located on glasssubstrate 134. As will be appreciated, in contrast to assemblies thatutilize an adhesive to bond a polymer frame to a cover glass component,the polymer material of melt bond 142 is the same as the material thatforms the rest of base 110, and melt bond 142 is formed from a single,contiguous, continuous piece of polymer material with the rest of base110.

In some embodiments, the liquid polymer material may be a thermoplasticmaterial that is solidified to form base 110 via cooling. In suchembodiments, mold body 402 and/or mold body 404 may include a coolingsystem, such as channels for conveying cooling liquid or gas throughmold bodies 402 and/or 404 to facilitate the quick solidification of theliquid polymer material to form base 110. In such embodiments, the moldcooling system also facilitates the maintenance of the temperature ofglass substrate below the maximum temperatures discussed herein. Inother embodiments, the liquid polymer material may be a polymer materialthat is cured via cross-linking, such as via UV curing. The liquidpolymer material may be a variety of suitable polymer materials forforming base 110, such as polyethylene, polypropylene,polycarbonate-ABS, thermoplastic elastomer, etc.

Following solidification, mold 400 is opened by moving mold body 402 and404 away from each other. As shown in FIG. 4F, the glass and framecomponent, shown as component 416, is separated from mold 400, and isremoved from mold 400. Following removal from mold 400, component 416 isassembled into the desired device, display, vehicle interior system,etc.

Following opening of mold 400, force 144 is no longer applied to glasssubstrate 134 to maintain the curved shape, but the engagement betweenthe solidified polymer material of base 110 and the glass and/or therigidity of the material of base 110 maintains or holds glass substrate134 in the curved shape as shown in FIG. 4F. In some embodiments, theengagement between base 110 and glass substrate 134 may include amechanical retaining feature such as a capture collar instead of or inaddition to the melt bond 142 discussed above. In such embodiments, themechanical structure is directly molded around glass substrate 134within mold 400 without the use of adhesives.

Mold bodies 402 and 404 may be formed from a variety of suitablematerials. In various embodiments, mold bodies 402 and/or 404 may beformed from plastic materials (e.g., PC-ABS, PVC, Delrin, etc.) ormetals (e.g., aluminum alloys, iron alloys, etc.). In variousembodiments, surface 408 of mold body 402 includes a coating materialthat limits or prevents scratches on glass substrate 134 during bendingand molding of base 110. Similarly, in various embodiments surface 410of mold body 404 includes a coating material that limits or preventsscratches on base 110 during molding.

In various embodiments, glass substrate 134 is formed from astrengthened glass sheet (e.g., a thermally strengthened glass material,a chemically strengthened glass sheet, etc.) In such embodiments, whenglass substrate 134 is formed from a strengthened glass material, firstmajor surface 136 and second major surface 138 are under compressivestress, and thus major surface 138 can experience greater tensile stressduring bending to the convex shape without risking fracture. This allowsfor strengthened glass substrate 134 to conform to more tightly curvedsurfaces.

A feature of a cold-formed glass substrate is an asymmetric surfacecompressive between the first major surface 136 and the second majorsurface 138 once the glass substrate has been bent to the curved shape.In such embodiments, prior to the cold-forming process or beingcold-formed, the respective compressive stresses in the first majorsurface 136 and the second major surface 138 of glass substrate 134 aresubstantially equal. After cold-forming, the compressive stress onconcave major surface 136 increases such that the compressive stress onthe major surface 136 is greater after cold-forming than beforecold-forming. In contrast, convex major surface 138 experiences tensilestresses during bending causing a net decrease in surface compressivestress on surface 138, such that the compressive stress in surface 138following bending is less than the compressive stress in surface 138when the glass sheet is flat.

As noted above, in addition to providing processing advantages such aseliminating expensive and/or slow heating steps, the cold-formingprocesses discussed herein are believed to generate curved glassarticles with a variety of properties that are superior to hot-formedglass articles, particularly for vehicle interior or display cover glassapplications. For example, Applicant believes that, for at least someglass materials, heating during hot-forming processes decreases opticalproperties of curved glass sheets, and thus, the curved glass substratesformed utilizing the cold-bending processes/systems discussed hereinprovide for both curved glass shapes along with improved opticalqualities not believed achievable with hot-bending processes.

Further, many glass surface treatments (e.g., anti-glare coatings,anti-reflective coatings, etc.) are applied via deposition processes,such as sputtering processes that are typically ill-suited for coatingcurved glass articles. In addition, many surface treatments (e.g.,anti-glare coatings, anti-reflective coatings, decorative coatings,etc.) also are not able to survive the high temperatures associated withhot-bending processes. Thus, in particular embodiments discussed herein,one or more surface treatments are applied to major surface 136 and/orto major surface 138 of glass substrate 134 prior to cold-bending, andglass substrate 134 including the surface treatment is bent to a curvedshape as discussed herein. Thus, Applicant believes that the processesand systems discussed herein allow for bending of glass after one ormore coating materials have been applied to the glass, in contrast totypical hot-forming processes.

It should be noted that in FIG. 3 , glass substrate 134 is shown havinga single curvature such that major surface 138 has a single convexradius of curvature and major surface 136 has a single concave radius ofcurvature. However, the method discussed herein allows for glasssubstrate 134 to be bent to more complex shapes. For example, as shownin FIG. 4F, glass substrate 134 is bent to a shape such that majorsurface 136 has both convex and concave curved sections, and majorsurface 138 has both convex and concaved curved sections, forming anS-shaped glass substrate when viewed in cross-section.

In various embodiments, a cold-formed glass substrate 134 may have acompound curve including a major radius and a cross curvature. Acomplexly curved cold-formed glass substrate 134 may have a distinctradius of curvature in two independent directions. According to one ormore embodiments, a complexly curved cold-formed glass substrate 134 maythus be characterized as having “cross curvature,” where the cold-formedglass substrate 134 is curved along an axis (i.e., a first axis) that isparallel to a given dimension and also curved along an axis (i.e., asecond axis) that is perpendicular to the same dimension. The curvatureof the cold-formed glass substrate and the curved display can be evenmore complex when a significant minimum radius is combined with asignificant cross curvature, and/or depth of bend. In variousembodiments, glass substrate 134 can have more than two curved regionswith the same or differing curved shapes. In some embodiments, glasssubstrate 134 can have one or more region having a curved shape with avariable radius of curvature.

Referring to FIG. 5 , additional structural details of glass substrate134 are shown and described. As noted above, glass substrate 134 has athickness T1 that is substantially constant and is defined as a distancebetween the first major surface 136 and the second major surface 138. Invarious embodiments, T1 may refer to an average thickness or a maximumthickness of the glass substrate. In addition, glass substrate 134includes a width W1 defined as a first maximum dimension of one of thefirst or second major surfaces orthogonal to the thickness T1, and alength L1 defined as a second maximum dimension of one of the first orsecond surfaces orthogonal to both the thickness and the width. In otherembodiments, W1 and L1 may be the average width and the average lengthof glass substrate 134, respectively.

In various embodiments, thickness T1 is 2 mm or less and specifically is0.3 mm to 1.1 mm. For example, thickness T1 may be in a range from about0.1 mm to about 1.5 mm, from about 0.15 mm to about 1.5 mm, from about0.2 mm to about 1.5 mm, from about 0.25 mm to about 1.5 mm, from about0.3 mm to about 1.5 mm, from about 0.35 mm to about 1.5 mm, from about0.4 mm to about 1.5 mm, from about 0.45 mm to about 1.5 mm, from about0.5 mm to about 1.5 mm, from about 0.55 mm to about 1.5 mm, from about0.6 mm to about 1.5 mm, from about 0.65 mm to about 1.5 mm, from about0.7 mm to about 1.5 mm, from about 0.1 mm to about 1.4 mm, from about0.1 mm to about 1.3 mm, from about 0.1 mm to about 1.2 mm, from about0.1 mm to about 1.1 mm, from about 0.1 mm to about 1.05 mm, from about0.1 mm to about 1 mm, from about 0.1 mm to about 0.95 mm, from about 0.1mm to about 0.9 mm, from about 0.1 mm to about 0.85 mm, from about 0.1mm to about 0.8 mm, from about 0.1 mm to about 0.75 mm, from about 0.1mm to about 0.7 mm, from about 0.1 mm to about 0.65 mm, from about 0.1mm to about 0.6 mm, from about 0.1 mm to about 0.55 mm, from about 0.1mm to about 0.5 mm, from about 0.1 mm to about 0.4 mm, or from about 0.3mm to about 0.7 mm. In other embodiments, the T1 falls within any one ofthe exact numerical ranges set forth in this paragraph.

In various embodiments, width W1 is in a range from 5 cm to 250 cm, fromabout 10 cm to about 250 cm, from about 15 cm to about 250 cm, fromabout 20 cm to about 250 cm, from about 25 cm to about 250 cm, fromabout 30 cm to about 250 cm, from about 35 cm to about 250 cm, fromabout 40 cm to about 250 cm, from about 45 cm to about 250 cm, fromabout 50 cm to about 250 cm, from about 55 cm to about 250 cm, fromabout 60 cm to about 250 cm, from about 65 cm to about 250 cm, fromabout 70 cm to about 250 cm, from about 75 cm to about 250 cm, fromabout 80 cm to about 250 cm, from about 85 cm to about 250 cm, fromabout 90 cm to about 250 cm, from about 95 cm to about 250 cm, fromabout 100 cm to about 250 cm, from about 110 cm to about 250 cm, fromabout 120 cm to about 250 cm, from about 130 cm to about 250 cm, fromabout 140 cm to about 250 cm, from about 150 cm to about 250 cm, fromabout 5 cm to about 240 cm, from about 5 cm to about 230 cm, from about5 cm to about 220 cm, from about 5 cm to about 210 cm, from about 5 cmto about 200 cm, from about 5 cm to about 190 cm, from about 5 cm toabout 180 cm, from about 5 cm to about 170 cm, from about 5 cm to about160 cm, from about 5 cm to about 150 cm, from about 5 cm to about 140cm, from about 5 cm to about 130 cm, from about 5 cm to about 120 cm,from about 5 cm to about 110 cm, from about 5 cm to about 110 cm, fromabout 5 cm to about 100 cm, from about 5 cm to about 90 cm, from about 5cm to about 80 cm, or from about 5 cm to about 75 cm. In otherembodiments, W1 falls within any one of the exact numerical ranges setforth in this paragraph.

In various embodiments, length L1 is in a range from about 5 cm to about250 cm, from about 10 cm to about 250 cm, from about 15 cm to about 250cm, from about 20 cm to about 250 cm, from about 25 cm to about 250 cm,from about 30 cm to about 250 cm, from about 35 cm to about 250 cm, fromabout 40 cm to about 250 cm, from about 45 cm to about 250 cm, fromabout 50 cm to about 250 cm, from about 55 cm to about 250 cm, fromabout 60 cm to about 250 cm, from about 65 cm to about 250 cm, fromabout 70 cm to about 250 cm, from about 75 cm to about 250 cm, fromabout 80 cm to about 250 cm, from about 85 cm to about 250 cm, fromabout 90 cm to about 250 cm, from about 95 cm to about 250 cm, fromabout 100 cm to about 250 cm, from about 110 cm to about 250 cm, fromabout 120 cm to about 250 cm, from about 130 cm to about 250 cm, fromabout 140 cm to about 250 cm, from about 150 cm to about 250 cm, fromabout 5 cm to about 240 cm, from about 5 cm to about 230 cm, from about5 cm to about 220 cm, from about 5 cm to about 210 cm, from about 5 cmto about 200 cm, from about 5 cm to about 190 cm, from about 5 cm toabout 180 cm, from about 5 cm to about 170 cm, from about 5 cm to about160 cm, from about 5 cm to about 150 cm, from about 5 cm to about 140cm, from about 5 cm to about 130 cm, from about 5 cm to about 120 cm,from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, fromabout 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about5 cm to about 75 cm. In other embodiments, L1 falls within any one ofthe exact numerical ranges set forth in this paragraph.

In various embodiments, one or more radius of curvature (e.g., R1 shownin FIG. 3 ) of glass substrate 134 is about 60 mm or greater. Forexample, R1 may be in a range from about 60 mm to about 1500 mm, fromabout 70 mm to about 1500 mm, from about 80 mm to about 1500 mm, fromabout 90 mm to about 1500 mm, from about 100 mm to about 1500 mm, fromabout 120 mm to about 1500 mm, from about 140 mm to about 1500 mm, fromabout 150 mm to about 1500 mm, from about 160 mm to about 1500 mm, fromabout 180 mm to about 1500 mm, from about 200 mm to about 1500 mm, fromabout 220 mm to about 1500 mm, from about 240 mm to about 1500 mm, fromabout 250 mm to about 1500 mm, from about 260 mm to about 1500 mm, fromabout 270 mm to about 1500 mm, from about 280 mm to about 1500 mm, fromabout 290 mm to about 1500 mm, from about 300 mm to about 1500 mm, fromabout 350 mm to about 1500 mm, from about 400 mm to about 1500 mm, fromabout 450 mm to about 1500 mm, from about 500 mm to about 1500 mm, fromabout 550 mm to about 1500 mm, from about 600 mm to about 1500 mm, fromabout 650 mm to about 1500 mm, from about 700 mm to about 1500 mm, fromabout 750 mm to about 1500 mm, from about 800 mm to about 1500 mm, fromabout 900 mm to about 1500 mm, from about 950 mm to about 1500 mm, fromabout 1000 mm to about 1500 mm, from about 1250 mm to about 1500 mm,from about 60 mm to about 1400 mm, from about 60 mm to about 1300 mm,from about 60 mm to about 1200 mm, from about 60 mm to about 1100 mm,from about 60 mm to about 1000 mm, from about 60 mm to about 950 mm,from about 60 mm to about 900 mm, from about 60 mm to about 850 mm, fromabout 60 mm to about 800 mm, from about 60 mm to about 750 mm, fromabout 60 mm to about 700 mm, from about 60 mm to about 650 mm, fromabout 60 mm to about 600 mm, from about 60 mm to about 550 mm, fromabout 60 mm to about 500 mm, from about 60 mm to about 450 mm, fromabout 60 mm to about 400 mm, from about 60 mm to about 350 mm, fromabout 60 mm to about 300 mm, or from about 60 mm to about 250 mm. Inother embodiments, R1 falls within any one of the exact numerical rangesset forth in this paragraph.

As shown in FIG. 6 , glass substrate 134 can include one or more regions148 intended to show a display (e.g., an electronic display). Inaddition, a glass substrate according to some embodiments can be curvedin multiple regions 152 and 154 of the glass substrate and in multipledirections (i.e., the glass substrate can be curved about different axesthat may or may not be parallel) as shown in FIG. 6 . Accordingly,shapes and forms of the possible embodiments are not limited to theexamples shown herein. Glass substrate 134 can be shaped to have acomplex surface including multiple different shapes including one ormore flat sections, one or more conical sections, one or morecylindrical sections, one or more spherical sections, etc.

The various embodiments of the vehicle interior system may beincorporated into vehicles such as trains, automobiles (e.g., cars,trucks, buses and the like), sea craft (boats, ships, submarines, andthe like), and aircraft (e.g., drones, airplanes, jets, helicopters andthe like).

Strengthened Glass Properties

As noted above, glass substrate 134 may be strengthened. In one or moreembodiments, glass substrate 134 may be strengthened to includecompressive stress that extends from a surface to a depth of compression(DOC). The compressive stress regions are balanced by a central portionexhibiting a tensile stress. At the DOC, the stress crosses from apositive (compressive) stress to a negative (tensile) stress.

In various embodiments, glass substrate 134 may be strengthenedmechanically by utilizing a mismatch of the coefficient of thermalexpansion between portions of the article to create a compressive stressregion and a central region exhibiting a tensile stress. In someembodiments, the glass substrate may be strengthened thermally byheating the glass to a temperature above the glass transition point andthen rapidly quenching.

In various embodiments, glass substrate 134 may be chemicallystrengthened by ion exchange. In the ion exchange process, ions at ornear the surface of the glass substrate are replaced by—or exchangedwith—larger ions having the same valence or oxidation state. In thoseembodiments in which the glass substrate comprises an alkalialuminosilicate glass, ions in the surface layer of the article and thelarger ions are monovalent alkali metal cations, such as Li⁺, Na⁺, K⁺,Rb⁺, and Cs⁺. Alternatively, monovalent cations in the surface layer maybe replaced with monovalent cations other than alkali metal cations,such as Ag⁺ or the like. In such embodiments, the monovalent ions (orcations) exchanged into the glass substrate generate a stress.

Ion exchange processes are typically carried out by immersing a glasssubstrate in a molten salt bath (or two or more molten salt baths)containing the larger ions to be exchanged with the smaller ions in theglass substrate. It should be noted that aqueous salt baths may also beutilized. In addition, the composition of the bath(s) may include morethan one type of larger ions (e.g., Na+ and K+) or a single larger ion.It will be appreciated by those skilled in the art that parameters forthe ion exchange process, including, but not limited to, bathcomposition and temperature, immersion time, the number of immersions ofthe glass substrate in a salt bath (or baths), use of multiple saltbaths, additional steps such as annealing, washing, and the like, aregenerally determined by the composition of the glass substrate(including the structure of the article and any crystalline phasespresent) and the desired DOC and CS of the glass substrate that resultsfrom strengthening. Exemplary molten bath compositions may includenitrates, sulfates, and chlorides of the larger alkali metal ion.Typical nitrates include KNO₃, NaNO₃, LiNO₃, NaSO₄ and combinationsthereof. The temperature of the molten salt bath typically is in a rangefrom about 380° C. up to about 450° C., while immersion times range fromabout 15 minutes up to about 100 hours depending on glass substratethickness, bath temperature and glass (or monovalent ion) diffusivity.However, temperatures and immersion times different from those describedabove may also be used.

In one or more embodiments, the glass substrates may be immersed in amolten salt bath of 100% NaNO₃, 100% KNO₃, or a combination of NaNO₃ andKNO₃ having a temperature from about 370° C. to about 480° C. In someembodiments, the glass substrate may be immersed in a molten mixed saltbath including from about 5% to about 90% KNO₃ and from about 10% toabout 95% NaNO₃. In one or more embodiments, the glass substrate may beimmersed in a second bath, after immersion in a first bath. The firstand second baths may have different compositions and/or temperaturesfrom one another. The immersion times in the first and second baths mayvary. For example, immersion in the first bath may be longer than theimmersion in the second bath.

In one or more embodiments, the glass substrate may be immersed in amolten, mixed salt bath including NaNO₃ and KNO₃ (e.g., 49%/51%,50%/50%, 51%/49%) having a temperature less than about 420° C. (e.g.,about 400° C. or about 380° C.). for less than about 5 hours, or evenabout 4 hours or less.

Ion exchange conditions can be tailored to provide a “spike” or toincrease the slope of the stress profile at or near the surface of theresulting glass substrate. The spike may result in a greater surface CSvalue. This spike can be achieved by a single bath or multiple baths,with the bath(s) having a single composition or mixed composition, dueto the unique properties of the glass compositions used in the glasssubstrates described herein.

In one or more embodiments, where more than one monovalent ion isexchanged into the glass substrate, the different monovalent ions mayexchange to different depths within the glass substrate (and generatedifferent magnitudes stresses within the glass substrate at differentdepths). The resulting relative depths of the stress-generating ions canbe determined and cause different characteristics of the stress profile.

CS is measured using those means known in the art, such as by surfacestress meter (FSM) using commercially available instruments such as theFSM-6000, manufactured by Orihara Industrial Co., Ltd. (Japan). Surfacestress measurements rely upon the accurate measurement of the stressoptical coefficient (SOC), which is related to the birefringence of theglass. SOC in turn is measured by those methods that are known in theart, such as fiber and four point bend methods, both of which aredescribed in ASTM standard C770-98 (2013), entitled “Standard TestMethod for Measurement of Glass Stress-Optical Coefficient,” thecontents of which are incorporated herein by reference in theirentirety, and a bulk cylinder method. As used herein CS may be the“maximum compressive stress” which is the highest compressive stressvalue measured within the compressive stress layer. In some embodiments,the maximum compressive stress is located at the surface of the glasssubstrate. In other embodiments, the maximum compressive stress mayoccur at a depth below the surface, giving the compressive profile theappearance of a “buried peak.”

DOC may be measured by FSM or by a scattered light polariscope (SCALP)(such as the SCALP-04 scattered light polariscope available fromGlasstress Ltd., located in Tallinn Estonia), depending on thestrengthening method and conditions. When the glass substrate ischemically strengthened by an ion exchange treatment, FSM or SCALP maybe used depending on which ion is exchanged into the glass substrate.Where the stress in the glass substrate is generated by exchangingpotassium ions into the glass substrate, FSM is used to measure DOC.Where the stress is generated by exchanging sodium ions into the glasssubstrate, SCALP is used to measure DOC. Where the stress in the glasssubstrate is generated by exchanging both potassium and sodium ions intothe glass, the DOC is measured by SCALP, since it is believed theexchange depth of sodium indicates the DOC and the exchange depth ofpotassium ions indicates a change in the magnitude of the compressivestress (but not the change in stress from compressive to tensile); theexchange depth of potassium ions in such glass substrates is measured byFSM. Central tension or CT is the maximum tensile stress and is measuredby SCALP.

In one or more embodiments, the glass substrate may be strengthened toexhibit a DOC that is described as a fraction of the thickness T1 of theglass substrate (as described herein). For example, in one or moreembodiments, the DOC may be equal to or greater than about 0.05T1, equalto or greater than about 0.1T1, equal to or greater than about 0.11T1,equal to or greater than about 0.12T1, equal to or greater than about0.13T1, equal to or greater than about 0.14T1, equal to or greater thanabout 0.15T1, equal to or greater than about 0.16T1, equal to or greaterthan about 0.17T1, equal to or greater than about 0.18T1, equal to orgreater than about 0.19T1, equal to or greater than about 0.2T1, equalto or greater than about 0.21T1. In some embodiments, the DOC may be ina range from about 0.08T1 to about 0.25T1, from about 0.09T1 to about0.25T1, from about 0.18T1 to about 0.25T1, from about 0.11T1 to about0.25T1, from about 0.12T1 to about 0.25T1, from about 0.13T1 to about0.25T1, from about 0.14T1 to about 0.25T1, from about 0.15T1 to about0.25T1, from about 0.08T1 to about 0.24T1, from about 0.08T1 to about0.23T1, from about 0.08T1 to about 0.22T1, from about 0.08T1 to about0.21T1, from about 0.08T1 to about 0.2T1, from about 0.08T1 to about0.19T1, from about 0.08T1 to about 0.18T1, from about 0.08T1 to about0.17T1, from about 0.08T1 to about 0.16T1, or from about 0.08T1 to about0.15T1. In some instances, the DOC may be about 20 μm or less. In one ormore embodiments, the DOC may be about 40 μm or greater (e.g., fromabout 40 μm to about 300 μm, from about 50 μm to about 300 μm, fromabout 60 μm to about 300 μm, from about 70 μm to about 300 μm, fromabout 80 μm to about 300 μm, from about 90 μm to about 300 μm, fromabout 100 μm to about 300 μm, from about 110 μm to about 300 μm, fromabout 120 μm to about 300 μm, from about 140 μm to about 300 μm, fromabout 150 μm to about 300 μm, from about 40 μm to about 290 μm, fromabout 40 μm to about 280 μm, from about 40 μm to about 260 μm, fromabout 40 μm to about 250 μm, from about 40 μm to about 240 μm, fromabout 40 μm to about 230 μm, from about 40 μm to about 220 μm, fromabout 40 μm to about 210 μm, from about 40 μm to about 200 μm, fromabout 40 μm to about 180 μm, from about 40 μm to about 160 μm, fromabout 40 μm to about 150 μm, from about 40 μm to about 140 μm, fromabout 40 μm to about 130 μm, from about 40 μm to about 120 μm, fromabout 40 μm to about 110 μm, or from about 40 μm to about 100 μm. Inother embodiments, DOC falls within any one of the exact numericalranges set forth in this paragraph.

In one or more embodiments, the strengthened glass substrate may have aCS (which may be found at the surface or a depth within the glasssubstrate) of about 200 MPa or greater, 300 MPa or greater, 400 MPa orgreater, about 500 MPa or greater, about 600 MPa or greater, about 700MPa or greater, about 800 MPa or greater, about 900 MPa or greater,about 930 MPa or greater, about 1000 MPa or greater, or about 1050 MPaor greater.

In one or more embodiments, the strengthened glass substrate may have amaximum tensile stress or central tension (CT) of about 20 MPa orgreater, about 30 MPa or greater, about 40 MPa or greater, about 45 MPaor greater, about 50 MPa or greater, about 60 MPa or greater, about 70MPa or greater, about 75 MPa or greater, about 80 MPa or greater, orabout 85 MPa or greater. In some embodiments, the maximum tensile stressor central tension (CT) may be in a range from about 40 MPa to about 100MPa. In other embodiments, CS falls within the exact numerical rangesset forth in this paragraph.

Glass Compositions

Suitable glass compositions for use in glass substrate 134 include sodalime glass, aluminosilicate glass, borosilicate glass,boroaluminosilicate glass, alkali-containing aluminosilicate glass,alkali-containing borosilicate glass, and alkali-containingboroaluminosilicate glass.

Unless otherwise specified, the glass compositions disclosed herein aredescribed in mole percent (mol %) as analyzed on an oxide basis.

In one or more embodiments, the glass composition may include SiO₂ in anamount in a range from about 66 mol % to about 80 mol %, from about 67mol % to about 80 mol %, from about 68 mol % to about 80 mol %, fromabout 69 mol % to about 80 mol %, from about 70 mol % to about 80 mol %,from about 72 mol % to about 80 mol %, from about 65 mol % to about 78mol %, from about 65 mol % to about 76 mol %, from about 65 mol % toabout 75 mol %, from about 65 mol % to about 74 mol %, from about 65 mol% to about 72 mol %, or from about 65 mol % to about 70 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes Al₂O₃ in anamount greater than about 4 mol %, or greater than about 5 mol %. In oneor more embodiments, the glass composition includes Al₂O₃ in a rangefrom greater than about 7 mol % to about 15 mol %, from greater thanabout 7 mol % to about 14 mol %, from about 7 mol % to about 13 mol %,from about 4 mol % to about 12 mol %, from about 7 mol % to about 11 mol%, from about 8 mol % to about 15 mol %, from about 9 mol % to about 15mol %, from about 10 mol % to about 15 mol %, from about 11 mol % toabout 15 mol %, or from about 12 mol % to about 15 mol %, and all rangesand sub-ranges therebetween. In one or more embodiments, the upper limitof Al₂O₃ may be about 14 mol %, 14.2 mol %, 14.4 mol %, 14.6 mol %, or14.8 mol %.

In one or more embodiments, the glass article is described as analuminosilicate glass article or including an aluminosilicate glasscomposition. In such embodiments, the glass composition or articleformed therefrom includes SiO₂ and Al₂O₃ and is not a soda lime silicateglass. In this regard, the glass composition or article formed therefromincludes Al₂O₃ in an amount of about 2 mol % or greater, 2.25 mol % orgreater, 2.5 mol % or greater, about 2.75 mol % or greater, about 3 mol% or greater.

In one or more embodiments, the glass composition comprises B₂O₃ (e.g.,about 0.01 mol % or greater). In one or more embodiments, the glasscomposition comprises B₂O₃ in an amount in a range from about 0 mol % toabout 5 mol %, from about 0 mol % to about 4 mol %, from about 0 mol %to about 3 mol %, from about 0 mol % to about 2 mol %, from about 0 mol% to about 1 mol %, from about 0 mol % to about 0.5 mol %, from about0.1 mol % to about 5 mol %, from about 0.1 mol % to about 4 mol %, fromabout 0.1 mol % to about 3 mol %, from about 0.1 mol % to about 2 mol %,from about 0.1 mol % to about 1 mol %, from about 0.1 mol % to about 0.5mol %, and all ranges and sub-ranges therebetween. In one or moreembodiments, the glass composition is substantially free of B₂O₃.

As used herein, the phrase “substantially free” with respect to thecomponents of the composition means that the component is not activelyor intentionally added to the composition during initial batching, butmay be present as an impurity in an amount less than about 0.001 mol %.

In one or more embodiments, the glass composition optionally comprisesP₂O₅ (e.g., about 0.01 mol % or greater). In one or more embodiments,the glass composition comprises a non-zero amount of P₂O₅ up to andincluding 2 mol %, 1.5 mol %, 1 mol %, or 0.5 mol %. In one or moreembodiments, the glass composition is substantially free of P₂O₅.

In one or more embodiments, the glass composition may include a totalamount of R₂O (which is the total amount of alkali metal oxide such asLi₂O, Na₂O, K₂O, Rb₂O, and Cs₂O) that is greater than or equal to about8 mol %, greater than or equal to about 10 mol %, or greater than orequal to about 12 mol %. In some embodiments, the glass compositionincludes a total amount of R20 in a range from about 8 mol % to about 20mol %, from about 8 mol % to about 18 mol %, from about 8 mol % to about16 mol %, from about 8 mol % to about 14 mol %, from about 8 mol % toabout 12 mol %, from about 9 mol % to about 20 mol %, from about 10 mol% to about 20 mol %, from about 11 mol % to about 20 mol %, from about12 mol % to about 20 mol %, from about 13 mol % to about 20 mol %, fromabout 10 mol % to about 14 mol %, or from 11 mol % to about 13 mol %,and all ranges and sub-ranges therebetween. In one or more embodiments,the glass composition may be substantially free of Rb₂O, Cs₂O or bothRb₂O and Cs₂O. In one or more embodiments, the R20 may include the totalamount of Li₂O, Na₂O and K₂O only. In one or more embodiments, the glasscomposition may comprise at least one alkali metal oxide selected fromLi₂O, Na₂O and K₂O, wherein the alkali metal oxide is present in anamount greater than about 8 mol % or greater.

In one or more embodiments, the glass composition comprises Na₂O in anamount greater than or equal to about 8 mol %, greater than or equal toabout 10 mol %, or greater than or equal to about 12 mol %. In one ormore embodiments, the composition includes Na₂O in a range from aboutfrom about 8 mol % to about 20 mol %, from about 8 mol % to about 18 mol%, from about 8 mol % to about 16 mol %, from about 8 mol % to about 14mol %, from about 8 mol % to about 12 mol %, from about 9 mol % to about20 mol %, from about 10 mol % to about 20 mol %, from about 11 mol % toabout 20 mol %, from about 12 mol % to about 20 mol %, from about 13 mol% to about 20 mol %, from about 10 mol % to about 14 mol %, or from 11mol % to about 16 mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes less thanabout 4 mol % K₂O, less than about 3 mol % K₂O, or less than about 1 mol% K₂O. In some instances, the glass composition may include K₂O in anamount in a range from about 0 mol % to about 4 mol %, from about 0 mol% to about 3.5 mol %, from about 0 mol % to about 3 mol %, from about 0mol % to about 2.5 mol %, from about 0 mol % to about 2 mol %, fromabout 0 mol % to about 1.5 mol %, from about 0 mol % to about 1 mol %,from about 0 mol % to about 0.5 mol %, from about 0 mol % to about 0.2mol %, from about 0 mol % to about 0.1 mol %, from about 0.5 mol % toabout 4 mol %, from about 0.5 mol % to about 3.5 mol %, from about 0.5mol % to about 3 mol %, from about 0.5 mol % to about 2.5 mol %, fromabout 0.5 mol % to about 2 mol %, from about 0.5 mol % to about 1.5 mol%, or from about 0.5 mol % to about 1 mol %, and all ranges andsub-ranges therebetween. In one or more embodiments, the glasscomposition may be substantially free of K₂O.

In one or more embodiments, the glass composition is substantially freeof Li₂O.

In one or more embodiments, the amount of Na₂O in the composition may begreater than the amount of Li₂O. In some instances, the amount of Na₂Omay be greater than the combined amount of Li₂O and K₂O. In one or morealternative embodiments, the amount of Li₂O in the composition may begreater than the amount of Na₂O or the combined amount of Na₂O and K₂O.

In one or more embodiments, the glass composition may include a totalamount of RO (which is the total amount of alkaline earth metal oxidesuch as CaO, MgO, BaO, ZnO and SrO) in a range from about 0 mol % toabout 2 mol %. In some embodiments, the glass composition includes anon-zero amount of RO up to about 2 mol %. In one or more embodiments,the glass composition comprises RO in an amount from about 0 mol % toabout 1.8 mol %, from about 0 mol % to about 1.6 mol %, from about 0 mol% to about 1.5 mol %, from about 0 mol % to about 1.4 mol %, from about0 mol % to about 1.2 mol %, from about 0 mol % to about 1 mol %, fromabout 0 mol % to about 0.8 mol %, from about 0 mol % to about 0.5 mol %,and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes CaO in anamount less than about 1 mol %, less than about 0.8 mol %, or less thanabout 0.5 mol %. In one or more embodiments, the glass composition issubstantially free of CaO.

In some embodiments, the glass composition comprises MgO in an amountfrom about 0 mol % to about 7 mol %, from about 0 mol % to about 6 mol%, from about 0 mol % to about 5 mol %, from about 0 mol % to about 4mol %, from about 0.1 mol % to about 7 mol %, from about 0.1 mol % toabout 6 mol %, from about 0.1 mol % to about 5 mol %, from about 0.1 mol% to about 4 mol %, from about 1 mol % to about 7 mol %, from about 2mol % to about 6 mol %, or from about 3 mol % to about 6 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises ZrO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises ZrO₂ in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises SnO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises SnO₂ in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition may include an oxidethat imparts a color or tint to the glass articles. In some embodiments,the glass composition includes an oxide that prevents discoloration ofthe glass article when the glass article is exposed to ultravioletradiation. Examples of such oxides include, without limitation oxidesof: T1, V, Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo.

In one or more embodiments, the glass composition includes Fe expressedas Fe₂O₃, wherein Fe is present in an amount up to (and including) about1 mol %. In some embodiments, the glass composition is substantiallyfree of Fe. In one or more embodiments, the glass composition comprisesFe₂O₃ in an amount equal to or less than about 0.2 mol %, less thanabout 0.18 mol %, less than about 0.16 mol %, less than about 0.15 mol%, less than about 0.14 mol %, less than about 0.12 mol %. In one ormore embodiments, the glass composition comprises Fe₂O₃ in a range fromabout 0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18mol %, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol %to about 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, fromabout 0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about0.10 mol %, and all ranges and sub-ranges therebetween.

Where the glass composition includes TiO₂, TiO₂ may be present in anamount of about 5 mol % or less, about 2.5 mol % or less, about 2 mol %or less or about 1 mol % or less. In one or more embodiments, the glasscomposition may be substantially free of TiO₂.

An exemplary glass composition includes SiO₂ in an amount in a rangefrom about 65 mol % to about 75 mol %, Al₂O₃ in an amount in a rangefrom about 8 mol % to about 14 mol %, Na₂O in an amount in a range fromabout 12 mol % to about 17 mol %, K₂O in an amount in a range of about 0mol % to about 0.2 mol %, and MgO in an amount in a range from about 1.5mol % to about 6 mol %. Optionally, SnO₂ may be included in the amountsotherwise disclosed herein. It should be understood, that while thepreceding glass composition paragraphs express approximate ranges, inother embodiments, glass substrate 134 may be made from any glasscomposition falling with any one of the exact numerical ranges discussedabove.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is in no way intendedthat any particular order be inferred. In addition, as used herein, thearticle “a” is intended to include one or more than one component orelement, and is not intended to be construed as meaning only one.

It will be apparent to those skilled in the art that variousmodifications and variations can be made without departing from thespirit or scope of the disclosed embodiments. Since modifications,combinations, sub-combinations and variations of the disclosedembodiments incorporating the spirit and substance of the embodimentsmay occur to persons skilled in the art, the disclosed embodimentsshould be construed to include everything within the scope of theappended claims and their equivalents.

What is claimed is:
 1. A vehicle interior system comprising: a polymerframe comprising a curved support surface; and a glass substratedirectly coupled to the curved support surface of the frame, the glasssubstrate comprising: a first major surface; a second major surface; aminor surface connecting the first major surface and the second majorsurface; and a thickness in a range from 0.05 mm to 2 mm, wherein: theglass substrate has a curved shape such that the first major surface ofthe glass substrate includes a curved section, the curved section of thefirst major surface includes a first radius of curvature greater than 30mm and less than 5 m, the curved support surface of the frame directlyengages the first major surface of the glass substrate via a melt bond,the direct engagement and a rigidity of the polymer frame maintains thecurved shape of the glass substrate, and the melt bond extends to theminor surface such that an edge of the polymer frame is aligned with theminor surface.
 2. The vehicle interior system of claim 1, wherein nostructural adhesives are used to bond the glass substrate to the polymerframe.
 3. The vehicle interior system of claim 1, wherein the curvedsupport surface is a convex curved surface and the curved section of thefirst major surface is a concave curved section.
 4. The vehicle interiorsystem of claim 3, wherein the first major surface includes a secondcurved section, wherein the second curved section of the first majorsurface is a convex curved section.
 5. The vehicle interior system ofclaim 1, wherein the glass substrate comprises an asymmetric surfacecompressive stress distribution.
 6. The vehicle interior system of claim1, wherein the glass substrate includes an anti-reflective coating onthe first major surface.
 7. The vehicle interior system of claim 1,wherein the frame comprises any one of a center console, a dashboard, anarm rest, a pillar, a seat back, a floor board, a headrest, a doorpanel, a steering wheel and a portion of a housing of a free-standingdisplay.
 8. The vehicle interior system of claim 1, wherein the vehicleis any one of an automobile, a sea craft, and an aircraft.
 9. Thevehicle interior system of claim 1, wherein the glass substratecomprises cross-curvature.
 10. The vehicle interior system of claim 1,wherein the thickness is in a range from 0.7 mm to 1.5 mm.
 11. Thevehicle interior system of claim 1, wherein the first radius ofcurvature is from about 60 mm to about 1500 mm.
 12. A vehicle interiorsystem comprising: a polymer frame comprising a curved support surface;a glass substrate directly coupled to the curved support surface of theframe, the glass substrate comprising: a first major surface; a secondmajor surface; a minor surface connecting the first major surface andthe second major surface; and a thickness in a range from 0.5 mm to 1.5mm, wherein: the glass substrate has a curved shape such that the firstmajor surface of the glass substrate includes a curved section, thecurved section of the first major surface includes a first radius ofcurvature greater than 30 mm and less than 5 m, the curved supportsurface of the frame directly engages the first major surface of theglass substrate via a melt bond, and the engagement and a rigidity ofthe polymer frame maintains the curved shape of the glass substrate; anda mechanical structure that is directly molded around the glasssubstrate and attached to the glass substrate without an adhesive,wherein the mechanical structure retains the polymer frame to the glasssubstrate.
 13. The vehicle interior system of claim 12, wherein nostructural adhesives are used to bond the glass substrate to the polymerframe.
 14. The vehicle interior system of claim 12, wherein the curvedsupport surface is a convex curved surface and the curved section of thefirst major surface is a concave curved section.
 15. The vehicleinterior system of claim 14, wherein the first major surface includes asecond curved section, wherein the second curved section of the firstmajor surface is a convex curved section.
 16. The vehicle interiorsystem of claim 12, wherein the glass substrate comprises an asymmetricsurface compressive stress distribution.
 17. The vehicle interior systemof claim 12, wherein the glass substrate includes an anti-reflectivecoating on the first major surface.
 18. The vehicle interior system ofclaim 12, wherein the frame comprises any one of a center console, adashboard, an arm rest, a pillar, a seat back, a floor board, aheadrest, a door panel, a steering wheel and a portion of a housing of afree-standing display.
 19. The vehicle interior system of claim 12,wherein the vehicle is any one of an automobile, a sea craft, and anaircraft.
 20. The vehicle interior system of claim 12, wherein the glasssubstrate comprises cross-curvature.